Drums for transporting and feeding wire

ABSTRACT

A drum for transporting and feeding welding wire may comprise a hold-down bar opening. The hold-down bar opening enables access to and removal of a hold-down bar without requiring prior removal of an end surface of the drum or a drum lid. The drum may also comprise an access door. The access door enables access to the interior space of the drum when it is opened or removed from the first end surface. The access door allows for retrieval of a portion of a wire stored within the drum without need to remove an end surface of the drum or a drum lid.

FIELD

The present disclosure generally relates to containers used to transportand feed welding wire and, in particular, to drums used to transport andfeed welding wire for continuous welding processes.

BACKGROUND

During welding, the changeover from existing welding wire to new weldingwire can be both complicated and time-consuming. Continuous weldingprocesses allow welding wire to be continuously fed in order to avoidinterruptions, thus simplifying the process and improving efficiency.Although continuous welding processes are known, continuous welding isoften difficult in practice. There is a need for simplification andimprovement of continuous welding processes.

SUMMARY

According to one aspect of the present disclosure, a drum fortransporting and feeding welding wire has an outer surface that: definesan interior space, is centered around a longitudinal axis, extends alongthe longitudinal axis, and at least substantially surrounds a wirehaving proximal and distal ends. The drum further comprises a first endsurface at an angle to the longitudinal axis. The first end surfacecomprises a wire feeding opening. The drum also comprises a hold-downbar to limit movement of the coiled wire during transport. The outersurface of the drum comprises a hold-down bar opening to allow at leastone end of the hold-down bar to protrude out beyond the outer surface ofthe drum.

According to another aspect of the present disclosure, a drum fortransporting and feeding welding wire defines an interior space andcomprises a first end surface. The first end surface of the drumcomprises an access door defined at least in part by a gap in the firstend surface that extends from a wire feeding opening of the first endsurface toward a circumference of the drum. The access door isconfigured to enable access to the interior space of the drum when it isopened or removed from the first end surface.

According to another aspect of the present disclosure, a drum fortransporting and feeding welding wire comprises an outer surfacecentered around a longitudinal axis. The drum extends along thelongitudinal axis and at least substantially surrounds a coiled wire.The drum comprises an end surface at an angle to the longitudinal axis.The end surface comprises a wire feeding opening and an access door thatextends from the wire feeding opening. The access door is configured toenable access to the interior space of the drum when it is opened orremoved from the end surface.

According to another aspect of the present disclosure, a method forcontinuously feeding welding wire comprises the steps of: (a) providingfirst and second drums, each drum having: (1) a wire having proximal anddistal ends coiled around a longitudinal axis defining a space aroundthe longitudinal axis; (2) an outer surface centered around thelongitudinal axis, extending along the longitudinal axis, and at leastsubstantially surrounding the coiled wire; and (3) an end surface at anangle to the longitudinal axis, wherein the end surface comprises anaccess door and a wire feeding opening, wherein the proximal end of thewire protrudes through the wire feeding opening; (b) placing the seconddrum in proximity to the first drum; (c) opening the access door of thefirst drum to define a first drum hole; (d) retrieving the distal end ofthe wire from the first drum; (e) pulling the distal end of the wirefrom the first drum through the first drum hole; (f) retrieving theproximal end of the wire from the wire feeding opening of the seconddrum; and (g) joining the distal end of the wire from the first drum tothe proximal end of the wire from the second drum.

It is to be understood that both the foregoing general description andthe following detailed description describe various embodiments and areintended to provide an overview or framework for understanding thenature and character of the claimed subject matter. The accompanyingdrawings are included to provide a further understanding of the variousembodiments, and are incorporated into and constitute a part of thisspecification. The drawings illustrate the various embodiments describedherein, and together with the description serve to explain theprinciples and operations of the claimed subject matter.

BRIEF DESCRIPTION OF THE DRAWINGS

The following is a description of the examples depicted in theaccompanying drawings. The figures are not necessarily to scale, andcertain features and certain views of the figures may be shownexaggerated in scale or in schematic in the interest of clarity orconciseness.

FIG. 1 is a perspective view of a welding wire drum showing the accessdoor in a closed position.

FIG. 2 is a perspective view of a welding wire drum showing the accessdoor in an open position partially pivoted about a hinge.

FIG. 3 is a perspective view of a welding wire drum showing the accessdoor partially detached from the end surface.

FIG. 4 is a perspective view of a welding wire drum in which the drumlid has been removed to show the interior space of the drum.

FIG. 5 is a perspective view of two welding wire drums adjacent to eachother.

FIG. 6 is a perspective view of two welding wire drums showing how thewelding wire of one drum may be joined to the welding wire of a seconddrum.

The following reference characters are used in this specification:

-   10 Drum-   11 End surface-   12 Drum body-   13 Drum lid-   14 Wire feeding opening-   15 Access door-   16 Edge-   17 Finger hole-   18 Outer surface-   19 Hold-down bar opening-   20 Drum-   25 Access door-   30 Welding wire-   32 Starting or proximal end-   34 Finishing or distal end-   35 Anti-tangle ball-   40 Interior space-   50 Hold-down bar-   60 Welding wire-   62 Starting or proximal end-   64 Finishing or distal end-   70 Hold-down bar

The foregoing summary, as well as the following detailed description,will be better understood when read in conjunction with the figures. Itshould be understood that the claims are not limited to the arrangementsand instrumentality shown in the figures. Furthermore, the appearanceshown in the figures is one of many ornamental appearances that can beemployed to achieve the stated functions of the apparatus.

DETAILED DESCRIPTION

In the following detailed description, specific details may be set forthin order to provide a thorough understanding of embodiments of thepresent disclosure. However, it will be clear to one skilled in the artwhen disclosed examples may be practiced without some or all of thesespecific details. For the sake of brevity, well-known features orprocesses may not be described in detail. In addition, like or identicalreference numerals may be used to identify common or similar elements.

As shown in FIG. 1, a drum 10 has an end surface 11 and an outer surface18. The example drum 10 is substantially cylindrical in shape. In analternative embodiment, the drum 10 may be shaped, for example, as ahexagonal prism or octagonal prism. The example drum 10 comprises a drumbody 12 and a drum lid 13. In an alternative embodiment, the drum 10 maybe a single piece. The example drum lid 13 is removable from the drumbody 12. The drum 10 may be made of a recyclable material, such as fiberor cardboard.

The end surface 11 of the example drum 10 is a top surface (e.g., basedon an intended orientation of the drum 10 when in use). The end surface11 includes a wire feeding opening 14. Welding wire 30 may pass throughthe wire feeding opening 14. The example wire feeding opening 14 islocated in a central location of the end surface 11. The end surface 11includes an access door 15. The access door 15 may be defined by an areaof the end surface 11 that extends from the wire feeding opening 14. Insome examples, the access door 15 is substantially triangular ortrapezoidal in shape. The access door 15 may include a sector (in thegeometric sense) of the end surface 11 attached on an edge 16 of theaccess door 15 to the first end surface 11. One side of the access door15 may be cut or otherwise detached from the end surface 11 to allow theedge 16 of the access door 15 to function as either a hinge, as shown inFIG. 2 or a detachment edge, as shown in FIG. 3. When functioning as ahinge, the edge 16 allows the access door to pivot to enable access toan interior space 40 of the drum 10. Alternatively, when functioning asa detachment edge, the edge 16 allows the access door 15 to be removedto enable access to the interior space 40. The edge 16 may be scored orperforated to better enable the access door 15 to pivot about, or detachfrom, the edge 16. Adjacent the access door 15 may be located a fingerhole 17. The finger hole 17 enables easier lifting of, or access to, theaccess door 15.

The example drum 10 includes a hold-down bar opening 19 on an outersurface 18 of the drum 10. The hold-down bar opening 19 may extendthrough the drum lid 13, the drum body 12, or both. The hold-down baropening 19 may be a hole, a slit, or any other appropriate geometry. Thehold-down bar opening 19 allows for a portion of a hold-down bar 50 toextend beyond the outer surface 18 of the drum. The hold-down bar 50limits movement of the welding wire 30, particularly during transport ofthe drum 10. The end of the hold-down bar 50 may be bent to prevent thehold-down bar 50 from inadvertently sliding into the drum 10 and toprovide easier handling of the hold-down bar 50. The bend in the examplehold-down bar 50 is 90 degrees, but may have a greater or lesser angle.The inclusion of a hold-down bar opening 19 provides for access to andremoval of the hold-down bar 50 through the hold-down bar opening 19without prior removal of the drum lid 13. Typically, the hold-down bar50 is removed before beginning a welding process. Notably, the hold-downbar opening 19 may be used on a drum that is not used for a continuouswelding process, including a drum that does not have an access door 15.For ease of use, such a drum could be prepared with a length of weldingwire 30 protruding through a wire feeding opening 14 to allow a user tostart a non-continuous welding process without first needing to removethe drum lid.

As shown in FIG. 4, the interior space 40 of the example drum 10contains welding wire 30. The welding wire 30 has a starting (e.g.,proximal) end 32 and a finishing (e.g., distal) end 34. The drum 10 maybe provided with the starting end 32 protruding through the wire feedingopening 14, with a majority of the welding wire located within theinterior space 40 of the drum 10, including the finishing end 34. Theaccess door 15 provides access to the finishing end 34 without need forremoval of the end surface 11 or drum lid 13.

An anti-tangle ball 35 may be threaded onto the welding wire 30, similarto how a needle may be threaded onto a length of thread. The anti-tangleball 35 may be used to prevent kinks or bends forming in the wire duringwelding. The formation of kinks or bends can interrupt the wire feedingprocess, such that the welding process has to be stopped, which can havedetrimental practical and economic consequences. During welding, theanti-tangle ball will advance along the length of the welding wire 30from the starting end 32 towards the finishing end 34 as the weldingwire 30 is drawn. The anti-tangle ball 35 will preferably be formed of amaterial that has a weight but that is sufficiently lightweight so asnot to deform the welding wire 30. The anti-tangle ball 35 should besized so that it can pass through the space in the end surface 11defined by the access door 15.

As shown in FIG. 5, a second drum 20 may be placed in relative proximityto a first drum 10. The drums 10, 20 may be adjacent each other, orspaced further apart. Optionally, the access door 15 of the first drum10 may be placed adjacent the second drum 20. The second drum 20 maycomprise an access door 25 to allow access to a second welding wire 60contained in the second drum 20, including the finishing end 64 of thesecond welding wire 60. Each of the drums 10, 20 may comprise ahold-down bar 50, 70 (respectively) to limit movement of the weldingwires 30, 60, particularly during transport. The hold-down bar 50, 70for each drum should be removed before beginning a welding process. Forexample, the hold-down bar 50 may be removed before retrieving thestarting end 32 of the first welding wire 30. Similarly, the hold-downbar 70 may be removed prior to retrieving the starting end 62 of thesecond welding wire 60.

As shown in FIG. 6, the finishing end 34 of a first welding wire 30 maybe joined to the starting end 62 of a second welding wire 60. Thewelding wires 30, 60 may be joined by, for example, butt welding.Joining the welding wires 30, 60 allows for a continuous weldingprocess. Towards the end of drawing the first welding wire 30, theanti-tangle ball 35 will advance along the finishing end 34 of the firstwelding wire 30 onto the starting end 64 of the second welding wire 60.

Advantages of the drum 10 include that the hold-down bar 50 may beremoved through the hold-down bar opening 19 without having to firstremove the drum lid 13, that it makes it easier to retrieve thefinishing end 34 of welding wire 30 via the access door 15 withouthaving to first remove the drum lid 13, and that the drum lid 13 mayremain intact during welding (thus limiting the amount of dirt or debristhat may enter the interior space 40 during welding). These advantagesimprove the efficiency of welding processes. In particular, continuouswelding processes are made more efficient by using the hold-down baropening 19 and the access door 15. Further, the risk of needing to stopa continuous welding process.

Some of the elements described herein are identified explicitly as beingoptional, while other elements are not identified in this way. Even ifnot identified as such, it will be noted that, in some embodiments, someof these other elements are not intended to be interpreted as beingnecessary, and would be understood by one skilled in the art as beingoptional.

While the present method and/or system has been described with referenceto certain implementations, it will be understood by those skilled inthe art that various changes may be made and equivalents may besubstituted without departing from the scope of the present methodand/or system. In addition, many modifications may be made to adapt aparticular situation or material to the teachings of the presentdisclosure without departing from its scope. For example, systems,blocks, and/or other components of disclosed examples may be combined,divided, re-arranged, and/or otherwise modified. Therefore, the presentmethod and/or system are not limited to the particular implementationsdisclosed. Instead, the present method and/or system will include allimplementations falling within the scope of the appended claims, bothliterally and under the doctrine of equivalents.

The invention claimed is:
 1. A drum for transporting and feeding weldingwire comprising: an outer surface that defines an interior space, iscentered around a longitudinal axis, extends along the longitudinalaxis, and at least substantially surrounds a wire that is coiled aroundthe longitudinal axis and that has proximal and distal ends; a first endsurface at an angle to the longitudinal axis, the first end surfacecomprising a wire feeding opening; and a hold-down bar to limit movementof the wire during transport; wherein the outer surface of the drumcomprises a hold-down bar opening to allow at least one end of thehold-down bar to protrude out beyond the outer surface of the drum;wherein the hold-down bar comprises a bend that protrudes beyond theouter surface of the drum; wherein the first end surface of the drumcomprises an access door defined at least in part by a gap in the firstend surface that extends from the wire feeding opening of the first endsurface toward a circumference of the drum, and wherein the access dooris configured to enable access to the interior space of the drum whenthe access door is opened or removed from the first end surface; andwherein the first end surface comprises a finger hole adjacent to theaccess door to assist in opening or removing the access door.
 2. Thedrum of claim 1, wherein the bend comprises an angle of 90 degrees. 3.The drum of claim 1, wherein the wire feeding opening is located in thecenter of the first end surface.
 4. The drum of claim 1, wherein thedrum comprises a fiber drum.
 5. The drum of claim 1, wherein the accessdoor is openable by pivoting the access door away from the first endsurface around a hinge defined by the interface between the access doorand the first end surface.
 6. The drum of claim 1, wherein the accessdoor is removable by detaching the access door from the first endsurface.
 7. The drum of claim 1, wherein the access door issubstantially triangular or trapezoidal in shape.
 8. The drum of claim1, wherein the access door comprises a geometric sector of the first endsurface attached on an edge of the access door to the first end surface.9. The drum of claim 1, wherein the proximal end of the wire protrudesthrough the wire feeding opening, and wherein the access door isconfigured to enable access to the wire inside the drum when the accessdoor is opened or removed from the first end surface.
 10. The drum ofclaim 1, further comprising an anti-tangle ball threaded onto the wireto prevent the wire from tangling or inadvertently deforming.
 11. Thedrum of claim 10, wherein the access door is dimensioned to, when theaccess door is detached or moved, enable the anti-tangle ball to beremoved from the drum via an in situ location of the access door on thefirst end surface.
 12. The drum of claim 1, wherein the drum is preparedwith a length of welding wire protruding through the wire feedingopening to allow a user to start a non-continuous welding processwithout first needing to remove the first end surface.
 13. A system fortransporting and feeding welding wire comprising a first and second drumaccording to claim 1, wherein the distal end of the wire of the firstdrum is welded to the proximal end of the wire of the second drum. 14.The system of claim 13, wherein the first drum is placed adjacent thesecond drum.
 15. The system of claim 14, wherein the first and seconddrums are aligned such that the access door of the first drum isadjacent to the access door of the second drum.
 16. The system of claim13, further comprising an anti-tangle ball threaded onto the wire toprevent the wire from tangling or inadvertently deforming.
 17. Thesystem of claim 13, wherein hold-down bar of both the first and thesecond drum is removed before welding.
 18. The system of claim 13,wherein the first end surface of both the first and the second drumremains intact during welding.